Emissions Failure - Really High CO% (1 Viewer)

[Kevin Anderson]

I just took my 85 fj to retest the emissions after getting a new cat installed and I failed again. The CO% is through the roof and the new Cat didn't help anything.

High Speed Results:
HC - 152 Pass
CO% - 4.86 Fail !!!
CO2% - 12
O2% - 0
NOX ppm - 0
Dilution% 16.9

Low Speed Results:
HC - 203 pass
CO% - 5.38 FAIL!!!
CO2% - 11.8
O2% - 0
NOX ppm - 0
Dilution% 17.2

I'm sure this is an easy one for the experts around here. Something is obviously not working. This thing passed last year.

 

[5280Hawk]

e-85 my man,

I ran about a third of a tank of it in my 60 when i went in for my emissions test.

I was running a De-vaned smog pump and it still passed,

Mind you that Nothing in my emissions system had ever been replaced or modified beyond the smog pump.

heres a link to the thread i started about it.

https://forum.ih8mud.com/60-series-wagons/234195-air-pump-missing-its-hose-fittings.html

 

[Kevin Anderson]

Per the emissions manual I checked the AI system. I removed the air bypass hose from the air cleaner and it was discharging air before I even disconnected the hose from the VTV. Does this mean the ABV is not working?

I'll try the E-85. Thanks.

 

[Dynosoar]

Yo have no residual O2 so I would question the Air injection/abv system.


Dynosoar

 

[Kevin Anderson]

should I take the abv off and try to clean it? I read about people doing this. Also, guess it is in bypass mode and from a thread I read it could be the VSVs are bad or who know what else.

 

[Kevin Anderson]

i just pulled the abv off, fooled with it and then put it back on. I don't really know what it does but it seemed to be working alright. Regardless, still running in bypass mode. How do you force it out of bypass mode?

 

[Spike Strip]

I think you need the emissions manual --

Isn't there a link to a pdf of it, somewhere? Anyone ?

 

[ToyotaDon]

High CO and 0 O2 = running rich

I'm not real experienced with the FJ60, but you may need to check the O2 sensor and fuel control at the carb. The O2 sensor could be biased lean, which could also be caused by the AIR being directed to the manifold instead of the Cat or atmosphere.

If the O2 sensor shows that the exhaust is rich, then it's correct and you need to move on to the next thing, one of which would be the Coolant Temperature Sensor.

HTH

 

[Dynosoar]

There is no o2 sensor on a fj60.


Dynosoar

 

[NocalFJ60]

When I had CO that high I had to adjust the jets to finally pass. I don't think anything in the emission systems will bring it down to passing if you start out that rich. What is the history with your carb? Where are you located?

 

[2mbb]

According to the table below, the only time air should be discharged to the air cleaner is when the cat has a high temperature and the engine is not decellerating. If the thermo sensor has shorted out, it can cause the ABV to discharge to the air cleaner. Unplug the thermosensor and see if the ABV stops discharging to the air cleaner. If that doesn't work, you can try disconnecting the vacuum line from the top port on the ABV. If that works, VSV(2) may not be opening. Next, reconnect the vacuum tubing to the ABV and disconnect the vacuum tube from the ASV. The tube should be pulling vacuum. If not, check VSV(1) for operation. If you do find vacuum, check the ASV diapharagm with a vacuum pump to see if it will hold vacuum.

If everything still seems OK, I guess there could be either a problem with your relief valve (stuck open) or the check valves (stuck closed)...Good luck.

 

[Kevin Anderson]

I will try this today. Thanks for the detailed response.

I'm in Austin, Texas btw.

 

[Marc311]

x2 on what 2mmb said. Those VSVs always go out (and they are no longer availible as far as I know - so you need to buy used).

You can manually apply vacuum to control your ABV to determine if it is functioning.

The FSM is availible online - I highly recommend you get hold of it. Having a process to go through really helps your frustration level when dealing with the multiple systems/parts of the FJ60 emmissions system.

That all being said, when I was having smog issues fixing the AI system had a negligible effect on my results. I think the things which have the biggest effect are the cat (which you have replaced already), making sure your carb is in order, and having your engine tuned properly (timing, valves, plugs, cap, wires).

 

[hank14]

Here is some info on cleaning the ABV valve and testing the VSVs.
In my case, one of the VSVs was not working.

https://forum.ih8mud.com/60-series-wagons/158854-abv-vsv-smog-help.html

You really need an emissions FSM.

As suggested byMark, the tune up will really help as well.

 

[Kevin Anderson]

Wow, when it rains it pours. My water pump just went bad. Weeping like crazy. I tried disconnecting the thermal sensor on the cat and then the vac hose on the top of the abv and no luck, still discharging to the air cleaner. The vacuum seems weak. I installed all new vacuum lines last year so I'm pretty sure everything is in good shape. I guess I will call Cdan and order a new water pump and some hoses and get that fixed first. Now I just have to go find something else to drive in the meantime.

 

[ToyotaDon]

There is no o2 sensor on a fj60.


Dynosoar

Okay, I wasn't sure because AllData showed replacement times & torque specs, but I couldn't find anything about feedback fuel control.

Agreed, it is running too rich for the AIR system or Cat to clean up.

 

[NocalFJ60]

How do they test in Austin? Do they test on a dyno or at idle? If you are failing at idle, then it could be a simple adjustment of the idle mixture screw on the carb and adjusting the idling speed. Search for lean drop method or follow the procedure in the FSM.

 

[Kevin Anderson]

I'll look into the lean drop. I think I already drilled out the plug a while back to get to the screw. I'm going to order a water pump today.

 

[KingBeeIII]

I added a qt of denatured alcohol to my tank today before emissions. It almost cut my CO output in half. I failed emissions yesterday and posted up on my local forum since different states have different standards. The alcohol came up as an easy fix more than once and at less than $7 for the qt, I figured I'd give it a try. Sure enough, my '83 passed. Hope it helps.

 

[Spike Strip]

How much gas did you have in the tank when you added the Alcohol ?